Apparatus for applying noise reducer elements to tyres for vehicle wheels

ABSTRACT

Apparatus for applying noise reducing elements to tyres for vehicle wheels. The apparatus includes a loading station of stacks of noise reducing elements, an extraction station of noise reducing elements from each stack placed downstream of the loading station, and a conveyor placed downstream of the extraction station and extending along a predefined path. The conveyor is configured for supporting and advancing in a row the noise reducing elements extracted from the stacks which are then applied to a radially inner surface of the tyres. The extraction of each of the noise reducing elements contemplates: retaining a first noise reducing element placed at the base of a stack; raising the remaining noise reducing elements of the stack from the first noise reducing element; moving away the first noise reducing element according to a set path; and lowering the remaining noise reducing elements of the stack.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/853,643 filed on Apr. 20, 2020, which, in turn, is adivisional of U.S. patent application Ser. No. 16/062,336 filed on Jun.14, 2018, which, in turn, is the U.S. national stage of InternationalPatent Application PCT/IB2016/057072 filed internationally on Nov. 23,2016, which, in turn, claims priority to Italian Patent Application No.1020150000 87338 filed on Dec. 23, 2015, each of which are incorporatedby reference herein in their entirety.

DESCRIPTION Technical field of the invention

The present invention relates to a process and an apparatus for applyingnoise reducer elements to tyres for vehicle wheels.

The present invention falls within the field of processes andapparatuses for manufacturing tyres for vehicle wheels.

In particular, the present invention relates to a process and anautomatic or semi-automatic apparatus for applying noise reducerelements to tyres for vehicle wheels.

The term “automatic” is used to indicate a process and a device in whichsubstantially all the operations are carried out by mechanical devices(such as with electric, pneumatic, hydraulic actuation) preferablycontrolled by a control unit and by means of suitable software. The term“semi-automatic” is used to indicate a process and a device in whichmost of the implemented operations are carried out by the mechanicaldevices mentioned above and the operator's manual intervention isreduced to few and specific operations.

Background art

A tyre for vehicle wheels generally comprises a carcass structurecomprising at least one carcass ply having end flaps engaged withrespective annular anchoring structures. A belt structure is associatedin a radially outer position to the carcass structure, comprising one ormore belt layers, arranged in radial superposition with respect to eachother and with respect to the carcass ply, having textile or metallicreinforcing cords with crossed orientation and/or substantially parallelto the circumferential development direction of the tyre. A tread bandis applied in a position radially outer to the belt structure, also madeof elastomeric material like other semi-finished products making up thetyre. Respective sidewalls of elastomeric material are further appliedon the lateral surfaces of the carcass structure, each extending fromone of the lateral edges of the tread band up at the respective annularanchoring structure to the beads. In “tubeless” tyres, the carcass plyis internally coated by a preferably butyl-based layer of elastomericmaterial, usually called “liner” having optimal airtight characteristicsand extending from one to the other of the beads.

The term “elastomeric material” is used to designate a compositioncomprising at least one elastomeric polymer and at least onereinforcement filler. Preferably, such composition further comprisesadditives such as, for example, a cross-linking agent and/or aplasticiser. Due to the presence of the cross-linking agent, suchmaterial can be cross-linked by heating, so as to form the finalmanufactured article.

The expression “noise reducer element” means an element which, onceassociated with a radially inner surface of a tyre, has the ability toattenuate the noise produced by the tyre itself during use. This abilitycan be conferred to said element by the type of material, or materials,with which said element is made and/or by the shape of the same. Suchnoise reducer elements usually consist of blocks of porous material suchas, for example, foamed polymeric material.

By “equatorial plane” of the tyre it is meant a plane perpendicular tothe axis of rotation of the tyre and which divides the tyre into twosymmetrically equal parts.

The terms “radial” and “axial” and the expressions “radiallyinner/outer” and “axially inner/outer” are used referring to a directionperpendicular and a direction parallel to the axis of rotation of thetyre, respectively. The terms “circumferential” and “circumferentially”are used with reference to the direction of the annular development ofthe tyre, namely the rolling direction of the tyre.

Document EP2067633 describes a noise reduction device and a tyre, inwhich the tyre vibration and noise can be reduced. The noise reductiondevice comprises two main sound-absorbing elements adapted to change thesectional area of a cavity of the tyre and two auxiliary sound-absorbingelements arranged between the two main sound-absorbing elements.

Document EP2123491 describes a noise reduction device comprising atleast one sound-absorbing element made of porous material attached tothe inner surface of the tread portion of the tyre. The sound-absorbingelement may include a plurality of parts arranged spaced apart along acircumferential direction of the tyre.

SUMMARY

In this context, the Applicant has felt the need to increase theproductivity of the lines dedicated to the manufacture of tyres providedwith noise reducer elements and to improve the quality and performanceof this type of tyres.

The Applicant has in fact observed that the known noise reducer elementsvery often consist of blocks of porous material of substantiallyparallelepiped shape which are glued to the inner surface of the tyre.

The Applicant has observed that the blocks of porous material definingthe noise reducer elements have high friction coefficient surfacesthereof, so that the sliding between two or more blocks placed in mutualcontact is considerably difficult, as is the sliding of each block ofsurfaces designed for the transport and/or movement of the blocksthemselves.

The Applicant has further observed that such blocks of porous materialmay be made from larger blocks that are subsequently cut into desiredsizes and then packaged. Each bale can hold hundreds of noise reducerelements arranged in stacks of dozens of elements each.

The Applicant has noted that, due to the low propensity to slide withrespect to each other and with respect to the surfaces with which theycome in contact, the management of noise reducer elements, for examplemeant as handling of the single blocks starting from the bales, as wellas their transportation, is critical.

In particular, the Applicant has noted that the interaction of noisereducer elements with one another and with the surfaces with which theycome into contact makes it difficult to ensure the correct positionthereof in the different management steps of the same; in particular, itmay lead to inaccuracies in the positioning of said noise reducerelements downstream of the transport steps when they are provided topick-up and application devices of said elements on the tyres, thusimplying possible inefficiencies in the application step of the same tothe tyres.

In this context, the Applicant has therefore felt the need to interveneon the accuracy and repeatability with which said noise reducer elementsare managed to be subsequently applied to the tyre.

The Applicant has perceived that, in order to obviate theabove-mentioned drawbacks, it may be useful to manage, in a first step,such noise reducer elements sorted in stacks and then successively feedthe single noise reducer elements to a device for the application of thesame to tyres.

The Applicant has thus found that by picking up such stacks directlyfrom the bales containing the noise reducer elements and feeding them toan extraction station, in which individual single noise reducer elementsare extracted from at least one stack at a time, releasing them from theremaining reducer elements present in the stack, it is possible toconsiderably increase the above repeatability and accuracy.

According to one aspect thereof, the present invention therefore relatesto an apparatus for applying noise reducer elements to tyres for vehiclewheels.

The apparatus comprises: a loading station of stacks of noise reducerelements; an extraction station of noise reducer elements from eachstack, wherein said extraction station is placed downstream of theloading station.

Preferably, a conveyor is placed downstream of the extraction stationand extends along a predefined path, wherein said conveyor is configuredfor supporting and advancing in succession the noise reducer elementsextracted from the stacks.

Preferably, the extraction station comprises a first conveyor having afirst upper transport surface configured for supporting at least onestack at a time, wherein said first upper transport surface is movablealong a predefined direction.

Preferably, the extraction station comprises a retention deviceoperatively active above the first upper transport surface andconfigured for retaining a first noise reducer element placed at thebase of said at least one stack on the first upper transport surface.

Preferably, the extraction station comprises a movement deviceoperatively arranged above the first upper transport surface andconfigured for lifting or lowering the remaining noise reducer elementsof each stack. According to a different aspect thereof, the presentinvention relates to a process for applying noise reducer elements totyres for vehicle wheels.

The process comprises:

arranging at least one stack of noise reducer elements;

extracting said noise reducer elements one at a time from said at leastone stack.

Preferably, the process provides for feeding, in succession, said noisereducer elements extracted from the stack according to a pre-establishedpath.

Preferably, the process provides for picking up said noise reducerelements from said pre-established path.

Preferably, the process provides for applying said noise reducerelements to a radially inner surface of at least one tyre for vehiclewheels.

Preferably, extracting said noise reducer elements one at a timecomprises: retaining a first noise reducer element placed at the base ofsaid at least one stack; raising the remaining noise reducer elements ofsaid at least one stack with respect to said first noise reducerelement.

Preferably, extracting further comprises: moving away the first noisereducer element according to the pre-established path.

Preferably, extracting further comprises: lowering the remaining noisereducer elements of said at least one stack.

According to a different aspect, the present invention relates to aplant for building tyres for vehicle wheels, comprising: an apparatusfor building green tyres for vehicle wheels comprising building devicesfor building a green tyre; at least one moulding and vulcanisation unitoperatively arranged downstream of the building apparatus; at least oneapparatus for applying noise reducer elements to tyres for vehiclewheels according to the present invention. Preferably, said at least oneapparatus for applying noise reducer elements is operatively arrangeddownstream of said at least one moulding and vulcanisation unit.

According to a different aspect thereof, the present invention relatesto a process for manufacturing tyres for vehicle wheels, comprising:building green tyres; moulding and vulcanising the green tyres; applyingnoise reducer elements to the tyres according to the process of thepresent invention. Preferably, it is contemplated to apply the noisereducer elements to tyre after moulding and vulcanising said tyre.

The Applicant believes that the present invention allows feeding in anorderly way the noise reducer elements towards the tyres and applyingthem with accuracy and repeatability to said tyres.

The Applicant also believes that the present invention allows feeding alarge number of noise reducer elements in the unit of time, so as toincrease the productivity of the line.

The Applicant further believes that the present invention allowsmanaging the noise reducer elements reliably, thereby minimising therisks of standstill of the plant and without damaging and/or impairingthe functionality of said noise reducer elements.

The present invention, in at least one of the above aspects thereof, canexhibit one or more of the following preferred features.

Preferably, the noise reducer element comprises a sound-absorbingmaterial, preferably a polymeric foam, preferably polyurethane foam,preferably open cell.

Preferably, the noise reducer element has a thickness comprised betweenabout 20 mm and about 30 mm. Preferably, the noise reducer element has arectangular or square shape in plain view. Preferably, the noise reducerelement has a length (measured along the circumferential development ofthe tyre when it is installed therein) comprised between about 200 mmand about 250 mm, more preferably equal to about 220 mm. Preferably, thenoise reducer element has a width (measured along a rolling axis of thetyre when it is installed therein) comprised between about 100 mm andabout 180 mm, more preferably comprised between about 120 mm and about160 mm.

Preferably, each stack comprises a number of noise reducer elementscomprised between ten and forty, more preferably between twenty andthirty.

Preferably, the first upper transport surface is movable at a speed ofbetween about 30 m/min and about 60 m/min.

Preferably, the first conveyor has a length comprised between about 300mm and about 600 mm.

Preferably, the retention device comprises two first engagement elementsconfigured for acting on opposite sides of said first noise reducerelement.

Preferably, said two first engagement elements are placed at oppositelongitudinal sides of the first conveyor for acting against the oppositesides of said first noise reducer element parallel to the predefineddirection.

Preferably, said two first engagement elements face each other and aremovable between a first mutual approached position, in which they act onsaid opposite sides of said first noise reducer element, and a secondmutual moved-apart position, in which they are spaced from said oppositesides.

Preferably, the movement device comprises two second engagement elementsconfigured for acting on opposite sides of at least one of the remainingnoise reducer elements.

Preferably, said two second engagement elements face each other and aremovable between a first mutual approached position, in which they act onsaid opposite sides of said at least one of the remaining noise reducerelements, and a second mutual moved-apart position, in which they arespaced from said opposite sides.

Preferably, said second engagement elements are also movable between alowered position, close to the upper transport surface, and a raisedposition.

The extraction station therefore allows retaining the noise reducerelement resting thereon on the first conveyor and raising the otheroverlying noise reducer elements of the same stack without the risk ofdragging upwards also the noise reducer element at the base.

Preferably, each of the two first engagement elements comprises aplurality of first elongated elements configured for at least partiallypenetrating into the noise reducer elements.

Preferably, each of the two second engagement elements comprises aplurality of second elongated elements configured for at least partiallypenetrating into the noise reducer elements.

The first and second elongated elements are, for example, a sort ofneedles of such dimensions as to be able to penetrate into thesound-absorbing material and then exit therefrom without causing suchdamage as to impair the functionality thereof, once the noise reducerelements are mounted into the tyre.

Preferably, first elongated elements of each of the two first engagementelements are alternated along the predefined direction with the secondelongated elements of a respective second engagement element placed on asame side. In this way, the first and second elongated elements may alsoengage simultaneously in the same noise reducer element.

Preferably, each of the two first engagement elements comprises:

a first support plate;

a plurality of first elongated elements projecting from the firstsupport plate and side-by-side each other along a first row.

Preferably, each of the two second engagement elements comprises:

a second support plate;

a plurality of second elongated elements projecting from the secondsupport plate and side-by-side each other along a second row.

Preferably, the first elongated elements are alternated with the secondelongated elements.

Preferably, said second support plate has through notches configured forreceiving the first elongated elements.

Preferably, the retention device comprises two first actuators, eachconnected to a respective first support plate and configured for movingsaid first support plate between the first mutual approached positionand the second mutual moved-apart position.

Preferably, the movement device comprises two second actuators, eachconnected to a respective second support plate and configured for movingsaid second support plate between the first mutual approached positionand the second mutual moved-apart position.

Preferably, the movement device comprises two third actuators, eachconnected to a respective second support plate and configured for movingsaid second support plate between the lowered position and the raisedposition.

Preferably, the extraction station comprises two lateral partitionspositioned on opposite longitudinal sides for engaging against oppositesides of the stack, wherein each of said two lateral partitions hasvertical slits; wherein the first elongated elements and the secondelongated elements pass into said vertical slits and are free to slidein said vertical slits.

Preferably, the loading station comprises: a second conveyor having asecond upper transport surface configured for supporting a plurality ofstacks at a time, wherein said second upper transport surface is movablealong a predefined direction.

Preferably, the loading station comprises: an auxiliary conveyor havinga vertical transport surface extended alongside and along the secondupper transport surface and configured for receiving in abutment saidplurality of stacks supported by the second upper transport surface.

The loading station is configured for facilitating the work of anoperator who manually arranges the stacks onto the second conveyor,taking care to push them and place them sideways against the thirdconveyor. In addition to loading, the operator, with the aid of thethird conveyor, therefore performs a sort of pre-alignment of thestacks.

Preferably, the second conveyor and the auxiliary conveyor are driven bya single motor, preferably brushless, so as to impart the same transportspeed to said two conveyors. Preferably, said transport speed iscomprised between about 15 m/min and about 40 m/min. Preferably, thesecond conveyor and the auxiliary conveyor have a length comprisedbetween about 1000 mm and about 2000 mm.

Preferably, the apparatus comprises a lateral alignment station placedbetween the loading station and the extraction station, wherein saidlateral alignment station is configured for adjusting a lateral positionof each stack with respect to a reference. In other words, the lateralalignment station is configured for arranging the successive stackstravelling to the extraction station so that they enter properly intosaid extraction station.

Preferably, the lateral alignment station comprises a third conveyorhaving a third upper transport surface configured for supporting atleast one stack, wherein said third upper transport surface is movablealong a predefined direction.

Preferably, the third conveyor has a length comprised between about 300mm and about 600 mm. Preferably, a transport speed of the third conveyoris comprised between about 15 m/min and about 40 m/min.

Preferably, the lateral alignment station comprises a vertical abutmentsurface available in a reference position above the third uppertransport surface.

Preferably, the lateral alignment station comprises a pusher acting ontop of the third upper transport surface and configured for pushing atleast one stack at a time against said vertical abutment surface.

Preferably, said reference position and/or the stroke of the pusher maybe set according to the geometry and/or size of the noise reducerelements.

Preferably, the vertical abutment surface is movable between thereference position and a stand-by position spaced apart from the thirdupper transport surface. When said at least one stack moves to enterinto the lateral side alignment station or exit from the lateralalignment station, the vertical abutment surface is placed in thestand-by position so as to prevent said at least one stack fromscratching against it. In fact, the material of the noise reducerelements is such as to generate a high friction with the surfaces and tomove the stack as a whole and/or the component elements thereof out ofthe correct position.

Preferably, the apparatus comprises a control device placed between theloading station and the extraction station, wherein said control deviceis configured for verifying a vertical alignment of the noise reducerelements of each stack. The control device checks that the noise reducerelements forming a stack are correctly stacked, or that all the noisereducer elements have the same orientation.

Preferably, the control device is placed downstream of the lateralalignment station. Preferably, the control device is placed between thelateral alignment station and a subsequent station.

Preferably, the control device comprises at least one sensor configuredfor detecting the footprint of the stack. Preferably, said controldevice is of the optical type. Preferably, said sensor comprises atleast one photo-detector. Preferably, the optical sensor detects theimprint of the stack on the third conveyor to check the footprint ofsaid stack. Preferably, a position of said sensor may be set accordingto the geometry and/or size of the stacks/noise reducer elements.

Preferably, the apparatus comprises a defective stack removal stationplaced downstream of the control device. At least one stack at a timepasses in such a removal station and preferably stops waiting to enterinto the extraction station. If the stack just checked is not stackedproperly, it can then be discarded. For example, such a station allowsaccessibility by an operator who removes the defective stack before itenters into the extraction station, or an automatic discard device maybe provided.

Preferably, the defective stack removal station comprises: a fourthconveyor having a fourth upper transport surface configured forsupporting at least one stack at a time, wherein said fourth uppertransport surface is movable along a predefined direction. Preferably,said fourth upper transport surface is movable intermittently.Preferably, said fourth upper transport surface is movable at a speed ofbetween about 30 m/min and about 60 m/min. Preferably, the fourthconveyor has a length comprised between about 300 mm and about 600 mm.

Preferably, a station is provided for picking up the noise reducerelements from the conveyor and for applying said noise reducer elementsto a radially inner surface of at least one tyre for vehicle wheels.

Preferably, the conveyor comprises a fifth conveyor having a fifth uppertransport surface configured for supporting the noise reducer elements.Preferably, said fifth conveyor is placed between the extraction stationand the pick-up and application station.

Preferably, the process provides for arranging two side-by-side stacksof noise reducer elements and simultaneously extracting one noisereducer element from each of the two stacks. At each extraction, twoaligned noise reducer elements are extracted from two adjacent stacks.

The extraction is carried out from below, taking care to lift and removedetach the upper noise reducer elements from the first noise reducerelement placed at the base of the stack before dragging said first noisereducer element away along the predefined path.

Preferably, retaining comprises: retaining the first noise reducerelement at opposite sides of said first noise reducer element.Preferably, it is contemplated to act against the opposite sides of saidfirst noise reducer element parallel to the predefined direction.

Preferably, lifting comprises: engaging opposite sides of a second noisereducer element placed immediately above the first noise reducer elementand lifting said second noise reducer element. Preferably, it iscontemplated to act against the opposite sides of said second noisereducer element parallel to the predefined direction. The lifting of thesecond noise reducer element causes the lifting of the whole stackportion lying over the first noise reducer element.

Preferably, the first noise reducer element is resting on a firstconveyor. Preferably, moving away comprises: moving the first conveyoraway according to the pre-established path. The first noise reducerelement is extracted from underneath the stack after having verticallylifted up the upper elements and removed in a horizontal direction.

Preferably, lowering comprises: lowering the second noise reducerelement until it is rested on the first conveyor.

Preferably, it is contemplated to stop the first conveyor before restingthe second noise reducer element thereon.

In this way, any friction between noise reducer elements and/or withother surfaces is prevented.

Preferably, retaining the first noise reducer element comprises: atleast partially inserting first elongated elements in the opposite sidesof said first noise reducer element.

Preferably, engaging opposite sides of the second noise reducer elementcomprises: at least partially inserting second elongated elements in theopposite sides of said second noise reducer element.

Preferably, prior to moving away the first noise reducer elementaccording to the pre-established path, first elongated elements areextracted from opposite sides of the first noise reducer element.

Preferably, arranging at least one stack of noise reducer elementscomprises: picking up a plurality of stacks from a bale in which saidstacks are stored.

Preferably, arranging at least one stack of noise reducer elementscomprises: loading a plurality of stacks on a second conveyor andfeeding them one after the other to an extraction station.

Preferably, loading further comprises: leaning the stacks against avertical auxiliary conveyor.

Preferably, the process provides for manually picking up the stacks fromthe package.

Preferably, the process provides for manually loading the stacks on thesecond conveyor.

Preferably, the process provides for: adjusting a lateral position ofeach stack with respect to a reference before extracting said noisereducer elements one at a time from the stack.

Preferably, adjusting comprises: pushing each stacks against a verticalabutment surface.

Preferably, the process provides for: verifying a vertical alignment ofthe noise reducer elements of each stack before extracting said noisereducer elements one at a time from the stack.

Preferably, verifying comprises: detecting the footprint of the stack.

Further features and advantages will become more apparent from thedetailed description of a preferred but non-exclusive embodiment of anapparatus and a process for applying noise reducer elements to tyres forvehicle wheel in a plant and a process for manufacturing tyres forvehicle wheels according to the present invention.

DESCRIPTION OF THE DRAWINGS

Such description is given hereinafter with reference to the accompanyingdrawings, provided only for illustrative and, therefore, non-limitingpurposes, in which:

FIG. 1 schematically shows a plant for building tyres for vehicle wheelscomprising an apparatus for applying noise reducer elements to tyres forvehicle wheels according to the present invention;

FIG. 2 shows a detailed top view of the apparatus for applying noisereducer elements in FIG. 1;

FIG. 3 shows a lateral elevation view of the apparatus in FIG. 2;

FIG. 4 shows an enlarged top view of a station of the apparatus in FIGS.2 and 3;

FIG. 5 show a front elevation view of a half of the station in FIG. 4;

FIG. 6 show a lateral elevation view of some elements of the station inFIG. 4;

FIGS. 7A-7I and 7L show respective operating configurations in thestation shown in FIGS. 4, 5 and 6;

FIG. 8 shows a radial half-section of a tyre built with the plant inFIG. 1;

FIG. 9 shows the tyre in FIG. 8 sectioned along a middle plane; and

FIG. 10 shows a perspective view of a noise reducer element configuredfor being installed in the tyre in FIG. 8.

DETAILED DESCRIPTION

With reference to FIG. 1, reference numeral 1 identifies as a whole aplant for building tyres 2 for vehicle wheels.

A tyre 2, built in said plant 1, is shown in FIG. 8 and essentiallycomprises a carcass structure 3 having two carcass plies 4 a, 4 b. Anairtight layer of elastomeric material or so-called liner 5 is appliedinternally to the carcass ply/plies 4 a, 4 b. Two annular anchoringstructures 6 comprising each a so-called bead core 6 a bearing anelastomeric filler 6 b in radially outer position are engaged torespective end flaps of the carcass ply or plies 4 a, 4 b. The annularanchoring structures 6 are integrated in the proximity of zones usuallyidentified by the name of “beads” 7, at which the engagement betweentyre 2 and a respective mounting rim usually occurs. A belt structure 8comprising belt layers 8 a, 8 b is circumferentially applied around thecarcass ply/plies 4 a, 4 b, and a tread band 9 is circumferentiallyoverlapped to the belt structure 8. The belt structure 8 can beassociated with so-called “under-belt inserts” 10 placed each betweenthe carcass ply/plies 4 a, 4 b and one of the axially opposite end edgesof the belt structure 8. Two sidewalls 11, extending each from therespective bead 7 to a corresponding lateral edge of the tread band 9,are applied in laterally opposite positions on the carcass plies 4 a, 4b.

Tyre 2 further comprises noise reducer elements 12 shaped as tiles,coupled to a radially inner surface of tyre 2 located at the tread band9.

The noise reducer elements 12 are placed astride of a middle plane “M”of tyre 2 and are arranged sequentially side by side, or slightly spacedapart, along the circumferential extension of tyre 2 itself (FIG. 9), ina number depending on the size of tyre 2.

Such noise reducer elements 12 are made of a sound-absorbing material,such as a polymeric foam, preferably of an open cell material, morepreferably of polyurethane foam. Their function is to attenuate thenoise produced by tyre 2 itself during use.

Each noise reducer element 12 may have a thickness “t” of between about10 mm and about 40 mm, and a width “W” (measured parallel to an axis ofrotation “X-X” of tyre 2) comprised between about 80 mm and about 200mm.

Plant 1 shown in FIG. 1 comprises a production line 13 of tyres 2consisting of a building apparatus 14 of green tyres 2 and at least onemoulding and vulcanisation unit 15 operatively arranged downstream ofthe building apparatus 14.

In the non-limiting embodiment of plant 1 shown in FIG. 1, the buildingapparatus 14 comprises a carcass building line 16 at which formingdrums, not shown, are moved between different stations of dispensingsemi-finished products designed to form, on each building drum, acarcass sleeve comprising the carcass plies 4 a, 4 b, liner 5, theannular anchoring structures and possibly at least part of sidewalls 11.

At the same time, in an outer sleeve building line 17, one or moreauxiliary drums, not shown, are sequentially moved between differentwork stations designed to form an outer sleeve on each auxiliary drum,comprising at least the belt structure 8, the tread band 9, and possiblyat least part of sidewalls 11.

The building apparatus 14 further comprises an assembling station, notshown, at which the outer sleeve is coupled to the carcass sleeve.

In other embodiments of plant 1, not shown, the building apparatus 14may be of different type, for example designed to form all of the abovecomponents on a single drum by means of building devices.

The built tyres 2 are then transferred to the moulding and vulcanisationunit 15.

As shown in FIG. 1, an apparatus 18 for applying noise reducer elements12 to tyres 2 is operatively located downstream of the moulding andvulcanisation unit 15.

The moulded and vulcanised tyres 2 are moved, by suitable devices notshown, from the moulding and vulcanisation unit 15 into apparatus 18 forapplying noise reducer elements 12.

Apparatus 18 comprises a conveyor belt or a motorised roller 19 forfeeding tyres 2 coming from the moulding and vulcanisation unit 15.

In the vicinity of the motorised roller 19, apparatus 1 comprises aloading station 20 of stacks 21 of noise reducer elements 12, anextraction station 22 of said noise reducer elements 12 from each stack21 placed downstream of the loading station 20, a conveyor 23 placeddownstream of the extraction station 22 and extending along a predefinedpath. The conveyor 23 is configured for supporting and advancing in asuccession the noise reducer elements 12 extracted from stacks 21. Theloading station 20 acts as a buffer for the noise reducer elements 12.

Each stack 21 may consist of a number of noise reducer elements 12 ofbetween about twenty and about thirty. In the accompanying drawings, forthe sake of clarity, each stack 21 comprises six or eight noise reducerelements 12.

A station 24 is arranged at a terminal end of conveyor 23 for picking upthe noise reducer elements 12 from conveyor 23 and applying said noisereducer elements 12 to the radially inner surface of tyres 2 carried bythe motorised roller 19.

Moreover, apparatus 18 comprises a lateral alignment station 25 placedbetween the loading station 20 and the extraction station 22, a controldevice 26 placed downstream of the loading station 20 and before theextraction station 22, a defective stack removal station 27 placeddownstream of the control device 26.

The extraction station 22 comprises a first conveyor 29 which has afirst upper transport surface 30 configured for supporting at least onestack 21 at a time. The first conveyor 29 has a length comprised betweenabout 300 mm and about 1000 mm. The first upper transport surface 30 ismovable at steps along a predefined direction “D” at a speed of betweenabout 20 m/min and about 60 m/min.

In the embodiment shown, the first conveyor 29 is a first conveyor beltwrapped on rollers and the upper transport surface 30 is defined by anupper branch of said first conveyor belt.

A retention device 31 is operatively active above the first uppertransport surface 30 and is configured for retaining a first noisereducer element 12′ placed at the base of said at least one stack 21 onthe first upper transport surface 30. Moreover, a movement device 32 isoperatively arranged above the first upper transport surface 30 and isconfigured for lifting or lowering the remaining noise reducer elements12 of each stack 21. The retention device 31 allows retaining the firstnoise reducer element 12′ resting thereon on the first conveyor 29 andraising the other overlying noise reducer elements 12 of the same stack21 without the risk of dragging upwards also the first noise reducerelement 12′ at the base.

The retention device 31 comprises (FIGS. 4, 5, 6) two first supportplates 33, each placed on one of the longitudinal sides of the firstconveyor 29. Said two first support plates 33 and the devices movingthem are substantially the same, whereby only one will be describedhereinafter.

The first support plate 33 carries a plurality of first elongatedelements 34 projecting from said first support plate 33 towards theother first support plate 33. The first elongated elements 34 lie in ahorizontal plane, are side by side and parallel to each other and arearranged along a first row.

As shown in FIGS. 4-6, the first support plate 33 is connected to afirst actuator 35. The first actuator 35 is configured for moving thefirst support plate 33 between a first approached position to the otherfirst support plate 33 and a second moved-away position. The firstactuator 35 is therefore is able to move the first support plate 33 andthe first elongated elements 34 along a horizontal directionsubstantially parallel to the first elongated elements 34 and orthogonalto the predefined direction of the first conveyor 29. In the embodimentshown, the first actuator 35 comprises a first guide 36 on which a firstslide 37 bearing the first support plate 33 translates. The firstactuator 35 may for example be of the electro-mechanical or pneumatictype.

The movement device 32 comprises two second support plates 38, eachplaced on one of the longitudinal sides of the first conveyor 29. Saidtwo second support plates 38 and the devices moving them aresubstantially the same, whereby only one will be described hereinafter.

The second support plate 38 carries a plurality of second elongatedelements 39 projecting from said second support plate 38 towards theother second support plate 38. The second elongated elements 39 lie in ahorizontal plane, are side by side and parallel to each other and arearranged along a second row.

The first and second elongated elements 34, 39 are a sort of needles ofsuch dimensions as to be able to penetrate into the sound-absorbingmaterial and then exit therefrom without causing such damage to saidsound-absorbing material as to impair the functionality thereof, oncethe noise reducer elements 12 are mounted into tyre 2.

As shown in FIGS. 4-6, the second support plate 38 is connected to asecond actuator 40 and to a third actuator 41.

The second actuator 40 is able to move the second support plate 38 andthe second elongated elements 39 along a horizontal directionsubstantially parallel to the second elongated elements 39 andorthogonal to the predefined direction of the first conveyor 29. In theembodiment shown, the second actuator 40 comprises a second guide 42 onwhich a second slide 43 bearing the second support plate 38 translates.The second actuator 40 may for example be of the electro-mechanical orpneumatic type.

The third actuator 41 is configured for moving said second support plate38 between a lowered position and a raised position. In the embodimentshown, the third actuator 41 comprises a third vertical guide 44 onwhich a third slide 45 bearing the second guide 42 is slidably mounted.The third actuator 41 is therefore able to move the second support plate38 and the second elongated elements 39 along a vertical directionbetween the lowered position, in which the second elongated elements 39lie at the same level of the first elongated elements 34, and the raisedposition, in which the seconds elongated elements 39 lie higher than thefirst elongated elements 34.

The second support plate 38 has, on a lower edge thereof, throughnotches 46 (FIG. 6) configured for accommodating the first elongatedelements 34 of the first support plate 33 when said second support plate38 is in the lowered position (FIGS. 5 and 6, the second support plate38 with the through notches 46 and the second elongated elements 39 areshown with dashed lines in the lowered position). The through notches 46are formed between second adjacent elongated elements 39 and the firstelongated elements 34 are vertically aligned with said through notches46, i.e. staggered with respect to the second elongated elements 39. Inother words, the first elongated elements 34 are alternated, along thepredefined direction, with the second elongated elements 39. In thisway, the first and second elongated elements 34, 39 may also engagesimultaneously in the same first noise reducer element 12′, as will bedescribed hereinafter.

The first support plates 33 with the respective first elongated elements34 are two first engagement elements configured for acting on oppositesides of said first noise reducer element 12′.

The second support plates 38 with the respective second elongatedelements 39 are two second engagement elements configured for acting onopposite sides of at least one of the remaining noise reducer elements12.

The extraction station 22 comprises two lateral partitions 47 positionedon opposite longitudinal sides of the first conveyor 29 for engagingagainst opposite sides of stack 21 positioned in the extraction station22. Each of said two lateral partitions 47 has vertical slits 48 (shownin FIG. 4), each placed at one of the first or second elongated elements34, 39. The first elongated elements 34 and the second elongatedelements 39 pass in said vertical slits 48 and are free to slide thereinduring their movements. Said lateral partitions 47 have the function ofpreventing, during the extraction, the first elongated elements 34and/or the second elongated elements 39 from remaining engaged in thenoise reducer elements 12 themselves.

The loading station 20 comprises: a second conveyor 49 having a secondupper transport surface 50 configured for supporting a plurality ofstacks 21 at a time. The second upper transport surface 50 is movablealong a predefined direction for bringing stacks 21 towards theextraction station 22. In the embodiment shown, the second conveyor 49is a second conveyor belt wrapped on rollers and the second uppertransport surface 50 is defined by an upper branch of said secondconveyor belt.

The loading station 20 further comprises an auxiliary vertical conveyor51 having a vertical transport surface 52 extending alongside and alongthe second upper transport surface 50. The auxiliary vertical conveyor51 is also an auxiliary conveyor belt wrapped on rollers and thevertical surface 52 is defined by a branch of said auxiliary conveyorbelt. The vertical surface 52 is configured for receiving a side ofstacks 21 supported by the second upper transport surface 50 inabutment.

The second conveyor 49 and the auxiliary conveyor 51 are preferablydriven by a single motor, not shown and for example brushless, so as toimpart the same transport speed to said two conveyors 49, 51.

The second upper transport surface 50 and the vertical transport surface52 therefore move jointly along the predefined direction and at atransport speed of between about 15 m/min and about 40 m/min. The secondconveyor 49 and the auxiliary conveyor 51 have a length comprisedbetween about 500 mm and about 2000 mm.

The lateral alignment station 25 comprises a third conveyor 53 having athird upper transport surface 54 configured for supporting at least onestack 21 at a time, wherein said third upper transport surface 54 ismovable along a predefined direction. The lateral alignment station 25is configured for adjusting a lateral position of each stack 21 withrespect to a reference. In the embodiment shown, the third conveyor 53is a third conveyor belt wrapped on rollers and the third uppertransport surface 54 is defined by an upper branch of said thirdconveyor belt. The third conveyor 53 has a length comprised betweenabout 300 mm and about 600 mm. The third upper transport surface 54moves in the predefined direction “D” at a transport speed of betweenabout 15 m/min and about 40 m/min.

A vertical abutment surface 55 is operationally active above the thirdupper transport surface 54 which is connected and moved by an actuator56, preferably pneumatic, able to move it between a reference position,in which said vertical abutment surface 55 lies on the third uppertransport surface 54, and a stand-by position, in which the verticalabutment surface 55 lies spaced apart from the third upper transportsurface. The vertical abutment surface 55 and the relevant actuator 56are placed at a longitudinal side of the third conveyor 53.

A pusher 53 is positioned on the opposite longitudinal side of saidthird conveyor 53 acting above the third upper transport surface 54.Pusher 57 is connected and driven by a respective actuator 58,preferably pneumatic, and is configured for pushing at least one stackat a time against the vertical abutment surface 54 when the latter is inthe reference position.

The control device 26 is arranged between the lateral alignment station25 and the subsequent defective stack 21 removal station 27 and isconfigured for checking the vertical alignment of the noise reducerelements of each stack 21. In one embodiment, the control device 26comprises a photo-detector placed above stacks 21 passing between thelateral alignment station 25 and the subsequent removal station 27. Thephoto-detector is able to detect whether stacks 21 fall into a maximumpredefined width.

The defective stack 21 removal station 27 comprises a fourth conveyor 59having a fourth upper transport surface 60 configured for supporting atleast one stack 21 at a time. The fourth upper transport surface 60 canbe moved along a predefined direction “D”.

In the embodiment shown, the fourth conveyor 59 is a fourth conveyorbelt wrapped on rollers and the fourth upper transport surface 60 isdefined by an upper branch of said fourth conveyor belt. The fourthconveyor 59 has a length comprised between about 300 mm and about 600mm. The fourth upper transport surface 60 moves in the predefineddirection “D” at a transport speed of between about 15 m/min and about40 m/min.

Conveyor 23 placed downstream of the extraction station 21 comprises afifth conveyor 67 having a fifth upper transport surface 68 configuredfor supporting the noise reducer elements 12 coming from the extractionstation 21. The fifth conveyor 67 has a length comprised between about300 mm and about 1000 mm. The fifth upper transport surface 68 moves inthe predefined direction “D” at a transport speed of between about 15m/min and about 40 m/min.

A device, not shown, is optionally active on the fifth conveyor 67,which allows packing, or arranging against one another, the noisereducer elements 12 placed in a succession

A control unit, not shown in the drawings, is operatively connected tothe loading station 20, to the lateral alignment station 25, to thecontrol device 26, to the extraction station 22, to conveyor 23, to thepick-up and application station 24 and to the motorised roller 19 inorder to check them according to the process according to the invention.

In use and according to the process according to the invention, tyres 2extracted from the moulding and vulcanisation unit or units 15 are fedonto the motorised roller 19 and are advanced with an intermittentmotion towards the terminal end of said motorised roller 19. One tyre 2at a time is therefore carried on said terminal end.

Meanwhile, an operator picks up a plurality of stacks 21 of noisereducer elements 12 from a bale, not shown, and manually loads them intothe loading station 20, laying them onto the second conveyor 49 andpushing them against the auxiliary vertical conveyor 51. In particular,a first noise reducer element 12 placed at the base of each stack 21 isresting on the second upper transport surface 50 and one side of thesame stack 12 is abutted against the second upper transport surface 52.Stacks 21 are therefore aligned in a row on the second conveyor 49. Forexample, the number of stacks 21 that may simultaneously lie in theloading station 20 is comprised between about ten and about thirty.

The second conveyor 49 is advanced in the predefined direction “D”together with the third conveyor 53 by one step, up to arranging a stack21 on the third upper transport surface 54. The third upper transportsurface 54 is stopped and the lateral position of stack 21 placed in thelateral alignment station 25 is adjusted with respect to a reference. Tothis end, when stack 21 is already stationary on the third uppertransport surface 54, the vertical abutment surface 55 is brought to thereference position (predefined according to the type of noise reducerelements 12 controlled at that time) that is usually already located inthe vicinity of one side of stack 12. Thereafter, pusher 57 pushes stack12 against said vertical abutment surface 55.

Once the lateral alignment has been performed, the third conveyor 53 isadvanced in the predefined direction “D” together with the fourthconveyor 59 by one step, up to arrange stack 21 on the fourth uppertransport surface 60, or in the defective stack removal station 27. Atthe same time, a subsequent stack 21 is brought from the loading station20 up to the lateral alignment station 25 to be subjected to the lateralalignment described above.

During the transit between the third conveyor 53 and the fourth conveyor59, stack 21 passes underneath the control device 26, which checks thevertical alignment of the noise reducer elements 12 belonging to such astack 21, i.e. checks that all the noise reducer elements 12 areoriented in the same way and that stack 21 still has the shape of aright parallelepiped.

In one embodiment, the control device 26 allows detecting the footprintof stack 21. For example, the control device 26 comprises aphoto-detector which projects a vertical electromagnetic beam placed ona side of stack 21. If stack 21 is properly organised, the verticalelectromagnetic beam does not intercept it and is not interrupted. Ifstack 21 has one or more elements 12 not organised, they intercept thevertical electromagnetic beam and the control device 26 detects themisalignment. The position of the electromagnetic beam may be adjustedaccording to the geometry of the noise reducer elements 12 controlled byapparatus 18.

In the defective stack removal station 27, stack 21 is stopped again andif it does not meet the vertical alignment requirements detected before,an operator or an automated system can remove it.

Once the vertical alignment has been checked, the fourth conveyor 59 isadvanced in the predefined direction “D” together with the firstconveyor 29 by one step, up to arrange stack 21 on the first uppertransport surface 30, or in the extraction station 22. At the same time,a subsequent stack 21 is carried from the lateral alignment station 25up to the defective stack removal station 27.

With stack 21 stationary on the first upper transport surface 30, thesingle noise reducer elements 12 are extracted sequentially startingfrom the lowest one (FIGS. 7A-7I and 7L).

To this end, stack 21 enters and stops in the extraction station 22while the first elongated elements 34 of the retention device 31 are inthe second mutual moved-apart position and also the second elongatedelements 39 of the movement device 32 are in the second mutualmoved-apart position and in the raised position (FIG. 7A). The firstelongated elements 34 are positioned on opposite sides of the firstnoise reducer element 12 placed at the base of stack 21. The secondelongated elements 39 are positioned on opposite sides of a second noisereducer element 12″ immediately above or in contact with the first noisereducer element 12′.

The first elongated elements 34 are brought (by the first actuators 35)to the mutual approached position and partially inserted into theopposite sides of the first noise reducer element 12′ and the secondelongated elements 39 are brought (by the second actuators 40) to themutual approached position and partially inserted into the oppositesides of the second noise reducer element 12″ (FIG. 7B). In this way,the first noise reducer element 12′ is retained on the first uppertransport surface 30.

While the first noise reducer element 12′ is retained on the first uppertransport surface 30, the second elongated elements 39 are moved to theraised position (by the third actuators 41) and they raise the secondnoise reducer element 12″ and all the other noise reducer elements 12placed above (FIG. 7C).

While the second noise reducer element 12″ is raised, the firstelongated elements 34 are brought (by the first actuators 35) to themutual moved-apart position and extracted from the opposite sides of thefirst noise reducer element 12′ (FIG. 7D).

Thereafter, the first conveyor 29 is activated and the first uppertransport surface 30 is advanced in the predefined direction “D” andaccording to the predetermined path together with the fifth uppertransport surface 68 of the fifth conveyor 67. In this way, the firstnoise reducer element 12″ is extracted from stack 21, without slidingagainst the second noise reducer element 12″ or against other surfacesof apparatus 18, and is fed according to the predetermined path andtowards the pick-up and application station 24 (FIG. 7E).

Once the first noise reducer element 12′ has been moved away from theremaining noise reducer elements 12 of stack 21, the first uppertransport surface 30 is stopped again. The second elongated elements 39,which are still inserted in the second noise reducer element 12″ andsupport it, are moved (by the third actuators 41) to the loweredposition up to rest the second noise reducer element 12″ on the firstupper transport surface 30 (FIG. 7F) and with the remaining noisereducer elements 12 of stack 21 resting on the second noise reducerelement 12″.

As described above, on each side, the first and second elongatedelements 34, 39 are alternated (FIG. 7G) and the first elongatedelements 34 are facing towards the through notches 46 of the firstsupport plate 33 which carries the respective first elongated elements34.

The first elongated elements 34 are returned (by the first actuators 35)to the mutual approached position and inserted into opposite sides ofthe second noise reducer element 12″ (FIG. 7H). In this step, the firstand second elongated elements 34, 39 co-exist within the second noisereducer element 12″. Notches 46 are placed astride of the firstelongated elements 34.

Thereafter, the second elongated elements 39 are extracted from thesecond noise reducer element 12″ (FIG. 71), then raised to the raisedposition and partially inserted in the opposite sides of a third noisereducer element 12″' (FIG. 7L). The cycle is then repeated until all thenoise reducer elements 12 of stack 21 have finished. Thereafter, asubsequent stack 21 is moved to the extraction station 22.

In an embodiment variant not shown, two or more stacks 21 at a time areinserted in the extraction station 22 (in a row and side by side),suitably sized, which simultaneously extracts two or more noise reducerelements at a time from the two or more stacks 21.

The noise reducer elements 12 arranged in succession one after theother, can move forward, carried by the fifth upper transport surface68, in groups, for example of three.

EXAMPLE

Assuming that ten stacks 21 can be loaded at a time in the loadingstation 20, in which each stack 21 comprises thirty noise reducerelements 12 (for a total of three hundred noise reducer elements 12) andconsidering that the time required to pick up a noise reducer element 12from conveyor 23 and apply it to a tyre 2 is about four seconds, theautonomy of the loading station 20 is about twenty minutes.

1. (canceled)
 2. A process for aligning stacks of noise reducingelements for tyres for vehicle wheels along a path of a plant forbuilding tyres for vehicle wheels, the process comprising: moving astack of noise reducing elements along a conveyor arrangement; andadjusting a lateral position of said stack with respect to a referenceby: moving an abutment surface to a reference position; and once thereference position is reached, pushing the stack against the abutmentsurface in the reference position.
 3. The process as claimed in claim 2,comprising: verifying a vertical alignment of the noise reducingelements of said stack.
 4. A process for extracting from a stack noisereducing elements for tyres for vehicle wheels, the process comprising:arranging at least one stack of noise reducing elements to move along aconveyor arrangement; pushing said at least one stack against anabutment surface; after said pushing, extracting said noise reducingelements one at a time from said at least one stack; and feeding, insuccession, said noise reducing elements extracted from the stack on theconveyor arrangement; wherein extracting said noise reducing elementsone at a time comprises: retaining a first noise reducing element placedin said at least one stack; lifting remaining noise reducing elements ofsaid at least one stack with respect to said first noise reducingelement; moving away the first noise reducing element; and lowering theremaining noise reducing elements of said at least one stack.
 5. Theprocess as claimed in claim 4, wherein said retaining comprises:retaining the first noise reducing element at opposite sides of saidfirst noise reducing element.
 6. The process as claimed in claim 5,wherein said lifting comprises: engaging opposite sides of a secondnoise reducing element placed immediately above the first noise reducingelement and lifting said second noise reducing element.
 7. The processas claimed in claim 6, wherein said retaining comprises: inserting, atleast partially, first elongated elements in the opposite sides of saidfirst noise reducing element.
 8. The process as claimed in claim 7,wherein engaging opposite sides of the second noise reducing elementcomprises: inserting, at least partially, second elongated elements inthe opposite sides of said second noise reducing element.
 9. The processas claimed in claim 8, wherein before moving away the first noisereducing element, first elongated elements are extracted from oppositesides of the first noise reducing element.
 10. The process as claimed inclaim 9, wherein said pushing comprises adjusting a lateral position ofeach of said at least one stack with respect to a reference beforeextracting said noise reducing elements one at a time from the at leastone stack.
 11. The process as claimed in claim 10, wherein saidreference is obtained by bringing the abutment surface to a referenceposition.
 12. The process as claimed in claim 11, comprising: verifyinga vertical alignment of the noise reducing elements of each at least onestack before extracting said noise reducing elements one at a time fromthe at least one stack.